Broken Board racks - 07 this time

[scoot18]

Hey just wanted to poll the group and refresh my memory of broken board racks. I know there has been a lot of discussion on 06 racks breaking, don't recall if anyone with 07 has had any broken racks.

Just got back for spending some time at Gaston, NC and had some trouble loosening up the bolt that secures the rack when in the outboard position, discovered that one of the bolts that secures the rack to the hinge block had broken and the rack was binding due to the weight of the boards not allowing the hand bolt to loosen. Not a problem, I just removed the boards and got a allen wrench and just removed the whole rack. I was lucky that the whole thing didn't break off while under way. I thought that the upgrades that were made 06 to 07 addressed this issue, anyone have any input? I will have to try to extract the bolt that is left in the hinge block (which will probably be tough, the other one that didn't break fought all of the way out I assume due to loctite) and just get another bolt, but I certainly don't want this to happen again.

Gonna make a call to the dealer tomorrow and get some advice and see if they can provide me with the same or similar bolts, wonder if there were any improvements to the grade or strength of the bolts?

[chpthril]

I have not heard any 07's breaking!

You could go to a grade8 bolt instead of SS.

[da.bell]

Same here, I haven't heard of any issues and the 2007 RZ isn't having issues with the racks either. Interesting that this happened..

[Weil Thing]

I noticed over the weekend that my port side rack is binding when opening and closing also...I'll be checking those screws this evening and let y'all know what I find. Glad you caught it before anyone could get hurt, Scoot!

[brody66]

I forgot to fold in the racks one time and hit the side of the lift with the rack, didnt break or anything, just bent a touch.

[scoot18]

I am going to try and extract the broken bolt again tonight, I already broke one extractor bit. Will see what happens.

Did talk to the dealer today, claims that this may be covered only for one year which was up back in April. He's going to call tige and see if they will assist. If I can get the threadlocked remainder out, all I will need is a few new bolts and wait until it reoccurs, or hopefully be able to keep a watchful eye out and possibly tighten or replace bolts before they break again.

Will let you know.

[Timmy!]

The '08 racks have a pin that you have to pull up on to release them in case that bolt were to break, never knew that!

Good luck with getting yours fixed!

[chpthril]

I am going to try and extract the broken bolt again tonight, I already broke one extractor bit. Will see what happens.

Did talk to the dealer today, claims that this may be covered only for one year which was up back in April. He's going to call tige and see if they will assist. If I can get the threadlocked remainder out, all I will need is a few new bolts and wait until it reoccurs, or hopefully be able to keep a watchful eye out and possibly tighten or replace bolts before they break again.

Will let you know.

07's have a 3yr warranty (parts only for 2nd an 3rd yr)

Take a rotary tool with a cutting wheel and cut a slot across the head of the broken bolt and use a flat-blade screwdriver to remove it. Just did this on a fork broken of an 07 22i.

[scoot18]

07's have a 3yr warranty (parts only for 2nd an 3rd yr)

Take a rotary tool with a cutting wheel and cut a slot across the head of the broken bolt and use a flat-blade screwdriver to remove it. Just did this on a fork broken of an 07 22i.

Wish that was possible, bolt broke off flush in the hinge block. I guess I could take a dye grinder and make a slot, but doing it would also cut into the aluminum hinge block.

If I cant extract the entire broken portion out, I will drill out the rest and just tap a new hole.

[chpthril]

Wish that was possible, bolt broke off flush in the hinge block. I guess I could take a dye grinder and make a slot, but doing it would also cut into the aluminum hinge block.

If I cant extract the entire broken portion out, I will drill out the rest and just tap a new hole.

Yes, you will end up with a half-moon groove in the alum block, but will not be noticeable when reassembled.

[scoot18]

Still unsuccessful at removing/extracting broken bolt. Stuart from NAMG has hooked me up and was able to get me a whole nother rack. Will be shipped directly to me, that is cool, much easier to swap out the whole thing. When I have more time I will revisit the extraction and keep on hand for some spare parts.

Thanks Stuart / tige`

[chpthril]

Wish that was possible, bolt broke off flush in the hinge block. I guess I could take a dye grinder and make a slot, but doing it would also cut into the aluminum hinge block.

If I cant extract the entire broken portion out, I will drill out the rest and just tap a new hole.

Scoot18,

Not sure what ever became of your broken bolt extraction. I had a fork get ripped off this weekend (1st in 3yrs) so I figure I would take some pics while I was doing my own extraction. The problem with easy-out type extractors is that SS is too soft, it will just chew up the screw.
With some sort of rotary tool with a cutting wheel, cut a slot in the head of the broken screw. Even if it's flush, you wont see the slots once remounted to the rack.

The trick is to find a large handled (for lots of torque) flat-blade screwdriver with a narrow enough blade to not bind interfere with the extraction. I ended up grinding one down to suit my needs.

Slots cut and both broken screws out in under 5 mins.

[ragboy]

man, I saw a tool on tv the other night, called "remove it" or something like that. Would do this in like 2 mins. It goes on your drill motor, and drills a smal cone in the bolt, then you put the other piece on that fits in the cone and grips and removes. I can't remember the name.

[dogbert]

Nice goin', McGuyver!

[R&T Babich]

I picked up a set of reverse drill bits and using a reversing drill have removed 6 or 7 broken bolts without a problem. Use the drill that is a bit smaller than the threads and a center punch to help keep it in the center. If the broken bolt is recessed find a sleeve to put over the bit to protect the threads which also aids in keeping it centered. So far every time I drill thru the broken bolt it spins out before I'm done drilling thru it.